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EP3289668B1 - Stator having adapted tooth geometry - Google Patents

Stator having adapted tooth geometry Download PDF

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Publication number
EP3289668B1
EP3289668B1 EP16716880.6A EP16716880A EP3289668B1 EP 3289668 B1 EP3289668 B1 EP 3289668B1 EP 16716880 A EP16716880 A EP 16716880A EP 3289668 B1 EP3289668 B1 EP 3289668B1
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EP
European Patent Office
Prior art keywords
projection
stator
circumferential direction
teeth
width
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EP16716880.6A
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German (de)
French (fr)
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EP3289668A1 (en
Inventor
Michael Sturm
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Ebm Papst Mulfingen GmbH and Co KG
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Ebm Papst Mulfingen GmbH and Co KG
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/14—Stator cores with salient poles
    • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/325—Windings characterised by the shape, form or construction of the insulation for windings on salient poles, such as claw-shaped poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
    • H02K3/345—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation between conductor and core, e.g. slot insulation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/16—Stator cores with slots for windings
    • H02K1/165—Shape, form or location of the slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
    • H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information

Definitions

  • the invention relates to a stator of an electric motor with teeth distributed in the circumferential direction, extending in the radial direction, and grooves provided between the teeth in which copper wire windings are received.
  • Electric motors are used with stators in environments with various degrees of pollution.
  • the distance to be maintained is determined by the air and creepage distances, whereby according to DIN VDE 0110-04.97 the air distance is defined as the shortest distance in air between two conductive parts, and the creepage distance is defined as the shortest distance along the surface an insulating material between two conductive parts.
  • the air and creepage distances must be much longer, especially when exposed to pollution and moisture, so that the surrounding air is not ionized by so-called pre-discharges and the breakdown can take place as a result. There must also be no creeping or sliding discharges along the surface of the insulation material.
  • a stator if a stator is to be used in an environment with heavier pollution (i.e. a higher degree of pollution), the clearance and creepage distance must be longer.
  • the values or distances to be observed here are defined by appropriate standard specifications. These depend on the requirements and the areas of application and are determined, for example, in the standards EN61800-5-1, EN60335-1, UL60730-1, UL1004-1 (-7) with reference to UL840.
  • stator package was completely encapsulated after winding, so that it is protected from environmental influences and contamination. This process is also very complex and also cost-intensive.
  • stator is completely coated with insulating powder paint.
  • stators must first be cleaned, preheated and then vortex sintered or coated one or more times. This process is also very time-consuming and costly.
  • the invention is therefore based on the object of increasing the air and creepage distances in a stator in a more economical manner without negatively affecting the performance and noise generation during operation.
  • the ability to insert insulation material into the grooves is to be improved.
  • a stator of an electric motor is proposed with teeth distributed in the circumferential direction, extending in the radial direction and grooves provided between the teeth, each adjacent teeth forming a groove opening (slot slot) on their radial outer edge sections and the radial outer edge sections of the teeth each forming one projection extending in the circumferential direction into the groove opening have, each of which forms a radially inwardly directed free contact surface for receiving an insulation.
  • the projections provided in the circumferential direction on the adjacent teeth and pointing towards one another make it possible to provide the insulation in the circumferential direction up to the slot opening and in the radial direction further outwards, so that the air and creepage distances from the wire windings received in the respective slots to the non-insulated Stator area is enlarged in the radial outer edge portions of its teeth. This enlargement of the clearance and creepage distance increases the degree of pollution in which the stator and therefore the electric motor can be used.
  • the structure according to the invention is adapted for internal rotor stators in that the teeth point radially inward.
  • Electric motors with the stator according to the invention can advantageously be used in connection with an open rotor and / or with an open motor / stator housing, which brings about optimal air cooling of the winding and the ball bearing. This enables new areas of application for conventional electric motors to be opened up.
  • the projections according to the invention on the teeth of the stator can achieve the higher degree of contamination while using the same installation space, i.e. adaptations to the geometry or the equipment of the electric motor are not necessary.
  • the projection provided on the teeth and pointing into the groove opening can also serve as a baffle surface for the extrusion coating process of the groove interior.
  • the projections enlarge the cross-section in the slot opening area, serve as a kind of flow aid for the injected insulation material and prevent overspray radially outwards and the formation of flakes in the slot opening (slot slot) which would negatively affect the winding process of the wire windings.
  • the insulation material hardens immediately on the contact surface due to the high temperature difference or becomes significantly less viscous and thus forms a protective barrier against splashing radially outwards. For the same reason, overspray can also be avoided when the tool is subsequently pressed.
  • the injection pressure and therefore the risk of splashing over in the slot opening area can also be reduced.
  • projections can serve as a flow aid, since the cross-sectional area for the encapsulation compound is enlarged and the slots in the stator are better filled as a result. This also has the consequence that the material thickness of the insulation layer can be reduced.
  • the respective projection forms part of an outer jacket surface of the stator radially on the outside.
  • the projections in the circumferential direction are designed as an extension of the outer edge of the respective teeth.
  • Insulation material can be introduced into the grooves up to an area of the projections which is located radially far outward.
  • the insulation material distributed up to the contact surfaces of the projections offers an enlarged distance or an enlarged air and creepage distance to the wire windings received radially further inside within the grooves.
  • the contact surface width in the circumferential direction corresponds to the projection width in the circumferential direction.
  • the size of the respective projection is thus determined by the width of the radially inwardly facing contact surface.
  • An inner section of the radial outer edge sections of the teeth that adjoins the projection immediately radially inward also has a rounded portion that is arched in the direction of the groove opening.
  • the respective projection forms an edge as the end of the contact surface, on which the rounding of the inner section is attached immediately follows.
  • predetermined radii, cage arches or free forms are included as exemplary embodiments of the rounding.
  • their design and size are adapted to the pole piece thickness as far as possible and with tangential transitions.
  • a ratio of pole shoe thickness to the radii is preferably set to a range between 0.5-1.5, more preferably 0.8-1.2.
  • the size of the respective projection is determined in an exemplary embodiment according to the invention in that a ratio of the projection width in the circumferential direction to a groove opening width in the circumferential direction is in a range from 0.1-0.15.
  • the projection width is selected to be as small as possible, but sufficiently large that the minimum insulation thickness of the encapsulation material can be reproduced.
  • a ratio of the projection width in the circumferential direction to the projection thickness in the radial direction is preferably set to a range of 0.5-1.0.
  • the intended size ratios ensure the advantages described above with regard to the air and creepage distances as well as the improved insertability of insulation material into the grooves.
  • the size ratios mentioned enable a sufficiently large proportion of iron in the stator material in the area of the slot opening, which has a direct positive effect on the magnetic circuit, i.e. the torque, the efficiency and the cogging torque.
  • the stator according to the invention is designed in an embodiment variant that it has a plurality of stator laminations in the axial direction, each with a certain axial stator laminate thickness, but the projection width provided is larger than the stator laminate thickness. Projections with the width according to the invention allow a sufficient Strength, can be punched reliably and withstand the high injection pressures when inserting the insulation material.
  • the shape of the respective projection has a rectangular cross-section in an axial plan view.
  • a non-sharp-edged design is expressly defined as a "rectangular cross-section", which includes punching radii of, for example, 0.15 mm due to manufacturing technology.
  • the invention also includes an embodiment of the stator with insulating encapsulation made of plastic in the grooves, the encapsulation covering at least one inner wall surface of the grooves and the radially inwardly directed free contact surface of the projection.
  • the wire windings preferably made of enamelled copper wire, are accommodated in the insulated grooves.
  • the projection width in the circumferential direction is between 0.1-1 mm.
  • the winding wire used has a predetermined wire diameter that is dependent on the motor design, the preferred ratio of the slot opening width to the wire diameter being 2.1-3.5, particularly preferably 2.5. As a result, the cogging torque behavior of the electric motor is particularly favorable.
  • the smallest possible groove opening width is selected. It is important to ensure that the winding wire can be laid economically and in terms of production technology.
  • FIG. 1 and 2 shows a stator 100 according to the prior art with teeth 101 distributed in the circumferential direction, with grooves 113 being provided between the teeth 101 for receiving winding wire 102.
  • the winding wires 102 are insulated from the stator lamination by an extrusion coating 114 in the grooves 113.
  • the embodiment shown has a relatively short air gap and creepage distance between the winding wire 102 and the stator lamination of the teeth 101, so that the stator is designed for use with pollution degree 2, pollution degree 2 is defined such that only non-conductive pollution occurs, occasionally however, temporary conductivity due to condensation must be expected.
  • FIGS. 3 and 4 show an embodiment of the stator 1 according to the invention as an external rotor stator for use in pollution degree 3, which is defined in such a way that conductive pollution or dry, non-conductive pollution occurs, which is therefore also conductive because condensation is to be expected. All for the embodiment according to Figure 3 disclosed features apply mutatis mutandis to the execution according to Figure 5 , in which the stator 1 according to the invention is shown as an internal rotor stator.
  • the basic structure of the stator 1 of the Figures 3 and 4 corresponds to that according to Figure 1 .
  • the stator 1 comprises teeth 11 extending in the radial direction with radial outer edge sections T-shaped in cross section and grooves 13 provided between the teeth 11, each adjacent teeth 11 forming a groove opening 15 on their radial outer edge sections, via which the winding wire 12 preferably is introduced into the grooves 13 by a needle and / or flyer winding.
  • the contamination also reaches the grooves 13 via the groove openings 15, which in the worst case can lead to a short circuit between the winding wire 12 and the teeth 11.
  • the radial outer edge sections of the teeth 11 each have on both sides a projection 2 which extends in the circumferential direction into the groove opening 15 and which in each case forms a radially inwardly directed free contact surface 3.
  • the projections 2 extend along the outer circumferential surface of the stator 1 and form a flush extension of the teeth 11 on the outside.
  • the contact surface 3 ends with an edge, which is immediately followed by the inner section 4 radially inward.
  • the inner section 4 is formed with a convex curve.
  • the size of the respective projection 2 is dimensioned such that the ratio b / a of the projection width b in the circumferential direction to the groove opening width a in the circumferential direction is 0.12.
  • the ratio b / c of the projection width b to the projection thickness c in the radial direction is set to 0.7.
  • the projection width b is defined as the width of the contact surface 3.
  • the groove opening width a is smallest. The above values refer to the slot opening width in this area.
  • the shape of the projection 2 has according to Figure 4 has a rectangular cross-section, taking into account the punching radii generated when punching the stator laminations.
  • Figure 3 shows the stator 1 with an insulating plastic encapsulation 14 injected into the grooves 13, which covers the entire inner wall surface of the grooves 13. In the area of the respective projection 2 extends
  • the extrusion coating comprises retaining lugs 7 which extend radially inward and prevent the winding wire 12 from sliding out of the groove opening 15.
  • the winding wire 12 used is an enamelled copper wire with a predetermined wire diameter that is dependent on the motor power.
  • the implementation of the invention is not restricted to the preferred exemplary embodiments specified above. Rather, a number of variants are conceivable which make use of the solution shown even in the case of fundamentally different designs.
  • the edge regions of the projections extending into the groove opening can be rounded in order to simplify the introduction of the wire winding needle.
  • the projection can in each case also have an axial groove which extends, for example, centrally along the projection.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Description

Die Erfindung betrifft einen Stator eines Elektromotors mit in Umfangsrichtung verteilten, sich in radialer Richtung erstreckenden Zähnen und jeweils zwischen den Zähnen vorgesehenen Nuten, in denen Kupferdrahtwicklungen aufgenommenen werden.The invention relates to a stator of an electric motor with teeth distributed in the circumferential direction, extending in the radial direction, and grooves provided between the teeth in which copper wire windings are received.

Elektromotoren werden mit Statoren in Umgebungen mit verschiedenen Verschmutzungsgraden eingesetzt. Je höher der Verschmutzungsgrad, desto weiter müssen die stromführenden Bauteile von leitenden Bauteilen entfernt werden, so dass es nicht zu einer ungewollten Entladung, d.h. einem Kurzschluss kommt. Der einzuhaltende Abstand wird dabei durch die Luft- und Kriechstrecke bestimmt, wobei gemäß DIN VDE 0110-04.97 die Luftstrecke definiert ist als kürzeste Entfernung in Luft zwischen zwei leitenden Teilen, und die Kriechstrecke definiert ist als kürzeste Entfernung entlang der Oberfläche eines Isolierstoffes zwischen zwei leitenden Teilen.Electric motors are used with stators in environments with various degrees of pollution. The higher the degree of pollution, the further the current-carrying components have to be removed from conductive components so that there is no unwanted discharge, ie a short circuit. The distance to be maintained is determined by the air and creepage distances, whereby according to DIN VDE 0110-04.97 the air distance is defined as the shortest distance in air between two conductive parts, and the creepage distance is defined as the shortest distance along the surface an insulating material between two conductive parts.

Die Luft- und Kriechstrecken müssen insbesondere bei Verschmutzungs- und Feuchtigkeitseinfluss sehr viel länger sein, so dass die umgebende Luft nicht durch sogenannte Vorentladungen ionisiert wird und dadurch der Durchschlag stattfinden kann. Auch dürfen keine Kriech- oder Gleitentladungen entlang der Oberfläche des Isolationswerkstoffs entstehen.The air and creepage distances must be much longer, especially when exposed to pollution and moisture, so that the surrounding air is not ionized by so-called pre-discharges and the breakdown can take place as a result. There must also be no creeping or sliding discharges along the surface of the insulation material.

Grundsätzlich gilt, dass wenn ein Stator in einer Umgebung mit stärkerer Verschmutzung (d.h. höherem Verschmutzungsgrad) eingesetzt werden soll, die Luft- und Kriechstrecke länger sein muss. Die hierbei einzuhaltenden Werte bzw. Abstände werden durch entsprechende Normvorgaben definiert. Diese sind abhängig von den Anforderungen sowie den Anwendungsgebieten und werden beispielsweise in den Normen EN61800-5-1, EN60335-1, UL60730-1, UL1004-1 (-7) mit Verweis auf UL840 bestimmt.Basically, if a stator is to be used in an environment with heavier pollution (i.e. a higher degree of pollution), the clearance and creepage distance must be longer. The values or distances to be observed here are defined by appropriate standard specifications. These depend on the requirements and the areas of application and are determined, for example, in the standards EN61800-5-1, EN60335-1, UL60730-1, UL1004-1 (-7) with reference to UL840.

Bei der Dimensionierung unterliegt man jedoch bauartbestimmten Restriktionen, so dass der Stator trotz der notwendigen Verlängerung der Luft- und Kriechstrecken aus wirtschaftlichen Gründen nicht vergrößert werden kann. Dabei sollen zudem auch die Leistung, das Drehmoment und der Wirkungsgrad nicht schlechter werden.When it comes to dimensioning, however, there are construction-specific restrictions so that the stator cannot be enlarged for economic reasons, despite the necessary lengthening of the clearances and creepage distances. In addition, the performance, torque and efficiency should not deteriorate.

Im Stand der Technik werden deshalb teilweise Deckschieber eingesetzt, bei denen die Überlappung jedoch relativ groß sein muss, um eine ausreichende Wirksamkeit zu gewährleisten. Der Prozess ist aufwändig und verschlechtert die Thermik.In the prior art, therefore, cover slides are sometimes used, in which the overlap must, however, be relatively large in order to ensure sufficient effectiveness. The process is laborious and worsens the thermals.

Alternativ wurde das Statorpaket nach dem Wickeln vollständig vergossen, so dass es vor Umwelteinflüssen und Verschmutzung geschützt ist. Auch dieser Prozess ist sehr aufwendig und zudem kostenintensiv.Alternatively, the stator package was completely encapsulated after winding, so that it is protected from environmental influences and contamination. This process is also very complex and also cost-intensive.

Auch gibt es im Stand der Technik Lösungen, bei denen der Stator vollständig mit Isolationspulverlack beschichtet wird. Hierzu müssen die Statoren jedoch zunächst gesäubert, vorgewärmt und anschließend ein oder mehrmals Wirbelgesintert bzw. beschichtet werden. Auch dieser Prozess ist sehr zeit- und kostenintensiv.There are also solutions in the prior art in which the stator is completely coated with insulating powder paint. To do this, however, the stators must first be cleaned, preheated and then vortex sintered or coated one or more times. This process is also very time-consuming and costly.

Bei herkömmlichen Statoren ist ferner bekannt, die Nuten mit Kunststoff auszuspritzen. Durch eine Vergrößerung der Nutöffnungsbreite kann dabei mehr Platz für die Umspritzung in der Nutöffnung geschaffen und die Luft- und Kriechstrecke vergrößert werden. Die Nutöffnung wird in der Fachsprache auch "Nutschlitze" genannt. Hierdurch geht jedoch eine unerwünschte Verschlechterung des Motorrastmoments einher, die negativen Einfluss auf die Geräuschentwicklung hat.In conventional stators, it is also known to inject plastic into the grooves. By increasing the width of the slot opening, more space can be created for the encapsulation in the slot opening and the clearance and creepage distance can be increased. The slot opening is also called "slot slot" in technical terms. This, however, is accompanied by an undesirable deterioration in the engine cogging torque, which has a negative influence on the development of noise.

Der Erfindung liegt deshalb die Aufgabe zugrunde, bei einem Stator die Luft- und Kriechstrecke auf wirtschaftlichere Weise zu vergrößern, ohne die Leistungsfähigkeit und Geräuschbildung im Betrieb negativ zu beeinflussen. Zudem soll die Einbringbarkeit von Isolationsmaterial in die Nuten verbessert werden.The invention is therefore based on the object of increasing the air and creepage distances in a stator in a more economical manner without negatively affecting the performance and noise generation during operation. In addition, the ability to insert insulation material into the grooves is to be improved.

Druckschriftlicher Stand der Technik im vorliegenden technischen Gebiet ist offenbart in den Dokumenten WO 2013/132775 A1 , JP 2002-335642 A , WO 2012/026158 A1 und EP 1 873 889 A2 .Prior art in the present technical field is disclosed in the documents WO 2013/132775 A1 , JP 2002-335642 A , WO 2012/026158 A1 and EP 1 873 889 A2 .

Diese Aufgabe wird gelöst durch eine Merkmalskombination gemäß Patentanspruch 1.This object is achieved by a combination of features according to patent claim 1.

Erfindungsgemäß wird dabei ein Stator eines Elektromotors mit in Umfangsrichtung verteilten, sich in radialer Richtung erstreckenden Zähnen und jeweils zwischen den Zähnen vorgesehenen Nuten vorgeschlagen, wobei jeweils benachbarte Zähne an ihren radialen Außenrandabschnitten jeweils eine Nutöffnung (Nutschlitz) bilden und die radialen Außenrandabschnitte der Zähne jeweils einen sich in Umfangsrichtung in die Nutöffnung erstreckenden Vorsprung aufweisen, der jeweils eine nach radial innen gerichtete freie Anlagefläche zur Aufnahme einer Isolierung bildet. Die in Umfangsrichtung an den benachbarten Zähnen vorgesehenen und zueinander weisenden Vorsprünge ermöglichen, die Isolierung in Umfangsrichtung bis zur Nutöffnung und in radialer Richtung bis weiter nach außen vorzusehen, so dass die Luft- und Kriechstrecke von den in den jeweiligen Nuten aufgenommenen Drahtwicklungen zu dem nicht isolierten Statorbereich in dessen radialen Außenrandabschnitte seiner Zähne vergrößert ist. Diese Vergrößerung der Luft- und Kriechstrecke erhöht den Verschmutzungsgrad, in dem der Stator und mithin der Elektromotor einsetzbar ist. Für Innenläuferstatoren wird der erfindungsgemäße Aufbau angepasst, indem die Zähne nach radial innen weisen.According to the invention, a stator of an electric motor is proposed with teeth distributed in the circumferential direction, extending in the radial direction and grooves provided between the teeth, each adjacent teeth forming a groove opening (slot slot) on their radial outer edge sections and the radial outer edge sections of the teeth each forming one projection extending in the circumferential direction into the groove opening have, each of which forms a radially inwardly directed free contact surface for receiving an insulation. The projections provided in the circumferential direction on the adjacent teeth and pointing towards one another make it possible to provide the insulation in the circumferential direction up to the slot opening and in the radial direction further outwards, so that the air and creepage distances from the wire windings received in the respective slots to the non-insulated Stator area is enlarged in the radial outer edge portions of its teeth. This enlargement of the clearance and creepage distance increases the degree of pollution in which the stator and therefore the electric motor can be used. The structure according to the invention is adapted for internal rotor stators in that the teeth point radially inward.

Elektromotoren mit dem erfindungsgemäßen Stator können vorteilhafterweise in Verbindung mit einem geöffneten Rotor und/oder mit einem geöffneten Motor-/Statorgehäuse eingesetzt werden, die eine optimale Luftkühlung der Wicklung und des Kugellagers mit sich bringt. Hierdurch können neue Anwendungsgebiete herkömmlicher Elektromotoren erschlossen werden.Electric motors with the stator according to the invention can advantageously be used in connection with an open rotor and / or with an open motor / stator housing, which brings about optimal air cooling of the winding and the ball bearing. This enables new areas of application for conventional electric motors to be opened up.

Ferner ist günstig, dass durch die erfindungsgemäßen Vorsprünge an den Zähnen des Stators der höhere Verschmutzungsgrad unter Nutzung desselben Bauraums erreicht werden kann, d.h. Anpassungen an der Geometrie oder der Ausstattung des Elektromotors sind nicht nötig.It is also advantageous that the projections according to the invention on the teeth of the stator can achieve the higher degree of contamination while using the same installation space, i.e. adaptations to the geometry or the equipment of the electric motor are not necessary.

Der jeweils an den Zähnen vorgesehene und in die Nutöffnung weisende Vorsprung kann ferner als Prallfläche für den Umspritzungsprozess des Nutinneren dienen. Die Vorsprünge vergrößern den Querschnitt im Nutöffnungsbereich, dienen als eine Art Fließhilfe für das eingespritzte Isolationsmaterial und verhindern dabei Überspritzer nach radial außen sowie Flitterbildung in der Nutöffnung (Nutschlitz), welche den Wicklungsprozess der Drahtwicklungen negativ beeinträchtigen würden. Beim Einspritzen von zunächst flüssigem heißem Isolationsmaterial - vornehmlich flüssigem Kunststoff - in die Nuten mit hohem Druck härtet das Isolationsmaterial an der Anlagefläche aufgrund des hohen Temperaturunterschieds sofort aus bzw. wird deutlich weniger viskos und bildet somit eine Schutzschranke gegen Überspritzer nach radial außen. Aus demselben Grund können auch Überspritzer beim späteren Werkzeugnachdruck vermieden werden. Durch die Erhöhung der Querschnittsfläche im Nutöffnungsbereich kann zudem der Einspritzdruck und mithin die Gefahr von Überspritzern im Nutöffnungsbereich reduziert werden.The projection provided on the teeth and pointing into the groove opening can also serve as a baffle surface for the extrusion coating process of the groove interior. The projections enlarge the cross-section in the slot opening area, serve as a kind of flow aid for the injected insulation material and prevent overspray radially outwards and the formation of flakes in the slot opening (slot slot) which would negatively affect the winding process of the wire windings. When injecting hot liquid insulation material - mainly liquid plastic - into the grooves high pressure, the insulation material hardens immediately on the contact surface due to the high temperature difference or becomes significantly less viscous and thus forms a protective barrier against splashing radially outwards. For the same reason, overspray can also be avoided when the tool is subsequently pressed. By increasing the cross-sectional area in the slot opening area, the injection pressure and therefore the risk of splashing over in the slot opening area can also be reduced.

Ein weiter vorteilhafter Effekt der Vorsprünge ist, dass diese als Fließhilfe dienen können, da sich die Querschnittsfläche für die Umspritzmasse vergrößert und dadurch die Nuten des Stators besser befüllt werden. Dies hat weiter zur Folge, dass die Materialdicke der Isolationsschicht reduziert werden kann.Another advantageous effect of the projections is that they can serve as a flow aid, since the cross-sectional area for the encapsulation compound is enlarged and the slots in the stator are better filled as a result. This also has the consequence that the material thickness of the insulation layer can be reduced.

In einer vorteilhaften Ausführungsvariante ist vorgesehen, dass der jeweilige Vorsprung radial außenseitig einen Teil einer Außenmantelfläche des Stators bildet. Das bedeutet, dass die Vorsprünge in Umfangsrichtung als Verlängerung des Außenrandes der jeweiligen Zähne ausgebildet sind. Isolationsmaterial kann bis zu einem radial weit außen liegenden Bereich der Vorsprünge in die Nuten eingebracht werden. Das bis an die Anlageflächen der Vorsprünge verteilte Isolationsmaterial bietet einen vergrößerten Abstand bzw. eine vergrößerte Luft- und Kriechstrecke zu den radial weiter innen innerhalb der Nuten aufgenommenen Drahtwicklungen.In an advantageous embodiment, it is provided that the respective projection forms part of an outer jacket surface of the stator radially on the outside. This means that the projections in the circumferential direction are designed as an extension of the outer edge of the respective teeth. Insulation material can be introduced into the grooves up to an area of the projections which is located radially far outward. The insulation material distributed up to the contact surfaces of the projections offers an enlarged distance or an enlarged air and creepage distance to the wire windings received radially further inside within the grooves.

In einer erfindungsgemäßen Ausführung ist vorgesehen, dass die Anlagenflächenbreite in Umfangsrichtung der Vorsprungsbreite in Umfangsrichtung entspricht. Die Größe des jeweiligen Vorsprungs wird somit durch die Breite der nach radial innen weisenden Anlagenfläche bestimmt. Ein sich unmittelbar radial einwärts an den Vorsprung anschließender Innenabschnitt der radialen Außenrandabschnitte der Zähne weist zudem eine in Richtung der Nutöffnung gewölbte Rundung auf. Das bedeutet, dass der jeweilige Vorsprung als Abschluss der Anlagenfläche eine Kante bildet, an die sich die Rundung des Innenabschnitts unmittelbar anschließt. Als Ausführungsbeispiele der Rundung sind erfindungsgemäß vorgegebene Radien, Korbbögen oder Freiformen umfasst. Deren Ausführung und Größe wird erfindungsgemäß weitestgehend und mit tangentialen Übergängen an die Polschuhdicke angepasst. Dabei wird ein Verhältnis von Polschuhdicke zu den Radien auf vorzugsweise auf einen Bereich zwischen 0,5 - 1,5, weiter bevorzugt 0,8 - 1,2 festgelegt.In an embodiment according to the invention it is provided that the contact surface width in the circumferential direction corresponds to the projection width in the circumferential direction. The size of the respective projection is thus determined by the width of the radially inwardly facing contact surface. An inner section of the radial outer edge sections of the teeth that adjoins the projection immediately radially inward also has a rounded portion that is arched in the direction of the groove opening. This means that the respective projection forms an edge as the end of the contact surface, on which the rounding of the inner section is attached immediately follows. According to the invention, predetermined radii, cage arches or free forms are included as exemplary embodiments of the rounding. According to the invention, their design and size are adapted to the pole piece thickness as far as possible and with tangential transitions. In this case, a ratio of pole shoe thickness to the radii is preferably set to a range between 0.5-1.5, more preferably 0.8-1.2.

Die Größe des jeweiligen Vorsprungs wird in einem erfindungsgemäßen Ausführungsbeispiel dadurch festgelegt, dass ein Verhältnis der Vorsprungsbreite in Umfangsrichtung zu einer Nutöffnungsbreite in Umfangsrichtung in einem Bereich von 0,1 - 0,15 liegt. Die Vorsprungsbreite wird möglichst klein jedoch ausreichend groß gewählt, dass die Mindestisolationsdicke des Umspritzungsmaterials abgebildet werden kann.The size of the respective projection is determined in an exemplary embodiment according to the invention in that a ratio of the projection width in the circumferential direction to a groove opening width in the circumferential direction is in a range from 0.1-0.15. The projection width is selected to be as small as possible, but sufficiently large that the minimum insulation thickness of the encapsulation material can be reproduced.

Ferner wird ein Verhältnis der Vorsprungsbreite erfindungsgemäß in Umfangsrichtung zur Vorsprungsdicke in radialer Richtung vorzugsweise auf einen Bereich von 0,5 - 1,0 festgelegt.Furthermore, according to the invention, a ratio of the projection width in the circumferential direction to the projection thickness in the radial direction is preferably set to a range of 0.5-1.0.

Die vorgesehenen Größenverhältnisse gewährleisten die oben beschriebenen Vorteile hinsichtlich der Luft- und Kriechstrecke sowie der verbesserten Einbringbarkeit von Isolationsmaterial in die Nuten. Zudem ermöglichen die genannten Größenverhältnisse einen ausreichend großen Eisenanteil des Statormaterials im Bereich der Nutöffnung, der unmittelbar positive Auswirkung auf den magnetischen Kreis, d.h. das Drehmoment, den Wirkungsgrad und das Rastmoment hat.The intended size ratios ensure the advantages described above with regard to the air and creepage distances as well as the improved insertability of insulation material into the grooves. In addition, the size ratios mentioned enable a sufficiently large proportion of iron in the stator material in the area of the slot opening, which has a direct positive effect on the magnetic circuit, i.e. the torque, the efficiency and the cogging torque.

Der erfindungsgemäße Stator ist in einer Ausführungsvariante ausgebildet, dass er in axialer Richtung eine Vielzahl von Statorblechen mit jeweils einer bestimmten axialen Statorblechdicke aufweist, wobei die vorgesehene Vorsprungsbreite jedoch größer dimensioniert ist als die Statorblechdicke. Vorsprünge mit der erfindungsgemäßen Breite ermöglichen eine ausreichende Festigkeit, sind prozesssicher stanzbar und widerstehen den hohen Einspritzdrücken beim Einbringen des Isolationsmaterials.The stator according to the invention is designed in an embodiment variant that it has a plurality of stator laminations in the axial direction, each with a certain axial stator laminate thickness, but the projection width provided is larger than the stator laminate thickness. Projections with the width according to the invention allow a sufficient Strength, can be punched reliably and withstand the high injection pressures when inserting the insulation material.

Die Form des jeweiligen Vorsprungs weist in einer günstigen Ausführungsform bei einer axialen Draufsicht einen rechteckigen Querschnitt auf. Als "rechteckiger Querschnitt" ist dabei ausdrücklich eine nicht scharfkantige Ausführung definiert, die fertigungstechnisch bedingte Stanzradien von beispielsweise 0,15mm mit umfasst.In a favorable embodiment, the shape of the respective projection has a rectangular cross-section in an axial plan view. A non-sharp-edged design is expressly defined as a "rectangular cross-section", which includes punching radii of, for example, 0.15 mm due to manufacturing technology.

Zur Erfindung gehört auch eine Ausführung des Stators mit isolierender Umspritzung aus Kunststoff in den Nuten, wobei die Umspritzung zumindest eine Innenwandfläche der Nuten und die nach radial innen gerichtete freie Anlagefläche des Vorsprungs überdeckt. In den isolierten Nuten werden die Drahtwicklungen, vorzugsweise aus Kupferlackdraht aufgenommen.The invention also includes an embodiment of the stator with insulating encapsulation made of plastic in the grooves, the encapsulation covering at least one inner wall surface of the grooves and the radially inwardly directed free contact surface of the projection. The wire windings, preferably made of enamelled copper wire, are accommodated in the insulated grooves.

In einem günstigen Anwendungsbeispiel von erfindungsgemäßen Statoren von Elektromotoren ist die Vorsprungsbreite in Umfangsrichtung zwischen 0,1 - 1mm.In a favorable application example of stators of electric motors according to the invention, the projection width in the circumferential direction is between 0.1-1 mm.

Der eingesetzte Wickeldraht weist einen vorbestimmten und von der Motorauslegung abhängigen Drahtdurchmesser auf, wobei das bevorzugte Verhältnis von Nutöffnungsbreite zu dem Drahtdurchmesser bei 2,1 - 3,5, insbesondere bevorzugt bei 2,5 liegt. Hierdurch ist das Rastmomentverhalten des Elektromotors besonders günstig. Vorzugsweise wird eine möglichst geringe Nutöffnungsbreite gewählt. Dabei ist darauf zu achten, dass der Wickeldraht fertigungstechnisch und wirtschaftlich verlegt werden kann.The winding wire used has a predetermined wire diameter that is dependent on the motor design, the preferred ratio of the slot opening width to the wire diameter being 2.1-3.5, particularly preferably 2.5. As a result, the cogging torque behavior of the electric motor is particularly favorable. Preferably, the smallest possible groove opening width is selected. It is important to ensure that the winding wire can be laid economically and in terms of production technology.

Andere vorteilhafte Weiterbildungen der Erfindung sind in den Unteransprüchen gekennzeichnet bzw. werden nachstehend zusammen mit der Beschreibung der bevorzugten Ausführung der Erfindung anhand der Figuren näher dargestellt. Es zeigen:

Fig. 1
einen Stator gemäß dem Stand der Technik in perspektivischer Ansicht,
Fig. 2
eine seitliche Teil-Schnittansicht des Stator aus Figur 1,
Fig. 3
eine seitliche Teil-Schnittansicht des erfindungsgemäßen Außen-läufer-Stators,
Fig. 4
eine Detailansicht von zwei benachbarten Statorzähnen eines Stators gemäß Figur 3 in einer Seitenansicht;
Fig. 5
eine seitliche Teil-Schnittansicht des erfindungsgemäßen Innen-läufer-Stators.
Other advantageous developments of the invention are characterized in the subclaims or are explained in more detail below together with the description of the preferred embodiment of the invention with reference to the figures shown. Show it:
Fig. 1
a stator according to the prior art in a perspective view,
Fig. 2
a side partial sectional view of the stator Figure 1 ,
Fig. 3
a side partial sectional view of the external rotor stator according to the invention,
Fig. 4
a detailed view of two adjacent stator teeth of a stator according to Figure 3 in a side view;
Fig. 5
a side partial sectional view of the inner rotor stator according to the invention.

In den Figuren 1 und 2 ist ein Stator 100 gemäß dem Stand der Technik mit in Umfangsrichtung verteilt angeordneten Zähnen 101 dargestellt, wobei zwischen den Zähnen 101 jeweils Nuten 113 zur Aufnahme von Wickeldraht 102 vorgesehen sind. Die Wickeldrähte 102 sind durch eine Umspritzung 114 in den Nuten 113 gegenüber dem Statorblech isoliert. Die gezeigte Ausführung weist eine relativ kurze Luft- und Kriechstrecke zwischen dem Wickeldraht 102 und dem Statorblech der Zähne 101 auf, so dass der Stator zum Einsatz bei einem Verschmutzungsgrad 2 ausgebildet ist, Verschmutzungsgrad 2 ist derart definiert, dass nur nicht leitfähige Verschmutzung auftritt, gelegentlich jedoch mit vorübergehender Leitfähigkeit durch Betauung gerechnet werden muss.In the Figures 1 and 2 shows a stator 100 according to the prior art with teeth 101 distributed in the circumferential direction, with grooves 113 being provided between the teeth 101 for receiving winding wire 102. The winding wires 102 are insulated from the stator lamination by an extrusion coating 114 in the grooves 113. The embodiment shown has a relatively short air gap and creepage distance between the winding wire 102 and the stator lamination of the teeth 101, so that the stator is designed for use with pollution degree 2, pollution degree 2 is defined such that only non-conductive pollution occurs, occasionally however, temporary conductivity due to condensation must be expected.

Die Figuren 3 und 4 zeigen ein Ausführungsbeispiel des erfindungsgemäßen Stators 1 als Außenläufer-Stator zum Einsatz in Verschmutzungsgrad 3, der derart definiert ist, dass leitfähige Verschmutzung oder trockene, nicht leitfähige Verschmutzung auftritt, die deshalb auch leitfähig wird, da Betauung zu erwarten ist. Sämtliche für das Ausführungsbeispiel gemäß Figur 3 offenbarten Merkmale gelten mutatis mutandis auch für die Ausführung gemäß Figur 5, in welcher der erfindungsgemäße Stator 1 als Innenläufer-Stator gezeigt ist.The Figures 3 and 4 show an embodiment of the stator 1 according to the invention as an external rotor stator for use in pollution degree 3, which is defined in such a way that conductive pollution or dry, non-conductive pollution occurs, which is therefore also conductive because condensation is to be expected. All for the embodiment according to Figure 3 disclosed features apply mutatis mutandis to the execution according to Figure 5 , in which the stator 1 according to the invention is shown as an internal rotor stator.

Der grundsätzliche Aufbau des Stators 1 der Figuren 3 und 4 entspricht demjenigen gemäß Figur 1. Der Stator 1 umfasst sich in radialer Richtung erstreckende Zähne 11 mit im Querschnitt T-förmigen radialen Außenrandabschnitten und jeweils zwischen den Zähnen 11 vorgesehenen Nuten 13, wobei jeweils benachbarte Zähne 11 an ihren radialen Außenrandabschnitten jeweils eine Nutöffnung 15 bilden, über die der Wickeldraht 12 vorzugsweise durch eine Nadel und/oder Flyerwickeln in die Nuten 13 eingebracht wird. Über die Nutöffnungen 15 gelangt auch die Verschmutzung in die Nuten 13, die im ungünstigsten Fall zum Kurzschluss zwischen dem Wickeldraht 12 und den Zähnen 11 führen kann. Zur Vermeidung ist bei der Ausbildung gemäß der Figuren 3 und 4 die Luft- und Kriechstrecke LK zwischen dem Wickeldraht 12 und dem leitenden Material der Zähne 11 gegenüber der aus dem Stand der Technik bekannten Lösung vergrößert. Die radialen Außenrandabschnitte der Zähne 11 weisen beidseitig jeweils einen sich in Umfangsrichtung in die Nutöffnung 15 erstreckenden Vorsprung 2 auf, der jeweils eine nach radial innen gerichtete freie Anlagefläche 3 bildet. Die Vorsprünge 2 erstrecken sich entlang der Außenmantelfläche des Stators 1 und bilden außenseitig einen bündigen Fortsatz der Zähne 11. Die Anlagefläche 3 endet mit einer Kante, an die sich unmittelbar radial einwärts der Innenabschnitt 4 anschließt. Der Innenabschnitt 4 ist mit einer konvexen Rundung ausgebildet.The basic structure of the stator 1 of the Figures 3 and 4 corresponds to that according to Figure 1 . The stator 1 comprises teeth 11 extending in the radial direction with radial outer edge sections T-shaped in cross section and grooves 13 provided between the teeth 11, each adjacent teeth 11 forming a groove opening 15 on their radial outer edge sections, via which the winding wire 12 preferably is introduced into the grooves 13 by a needle and / or flyer winding. The contamination also reaches the grooves 13 via the groove openings 15, which in the worst case can lead to a short circuit between the winding wire 12 and the teeth 11. In order to avoid this, the training according to Figures 3 and 4 the clearance and creepage distance LK between the winding wire 12 and the conductive material of the teeth 11 is increased compared to the solution known from the prior art. The radial outer edge sections of the teeth 11 each have on both sides a projection 2 which extends in the circumferential direction into the groove opening 15 and which in each case forms a radially inwardly directed free contact surface 3. The projections 2 extend along the outer circumferential surface of the stator 1 and form a flush extension of the teeth 11 on the outside. The contact surface 3 ends with an edge, which is immediately followed by the inner section 4 radially inward. The inner section 4 is formed with a convex curve.

In dem gezeigten Ausführungsbeispiel gemäß Figur 4 ist die Größe des jeweiligen Vorsprungs 2 derart dimensioniert, dass das Verhältnis b/a der Vorsprungsbreite b in Umfangsrichtung zur Nutöffnungsbreite a in Umfangsrichtung bei 0,12 liegt. Das Verhältnis b/c der Vorsprungsbreite b zur Vorsprungsdicke c in radialer Richtung ist auf 0,7 festgelegt. Die Vorsprungsbreite b ist dabei definiert als die Breite der Anlagefläche 3. Im Bereich des sich jeweils in Umfangsrichtung erstreckenden Vorsprungs 2 ist die Nutöffnungsbreite a am geringsten. Die oben genannten Werte beziehen sich auf die Nutöffnungsbreite in diesem Bereich. Die Form des Vorsprungs 2 weist gemäß Figur 4 einen rechteckigen Querschnitt auf, wobei die beim Stanzen der Statorbleche erzeugten Stanzradien zu berücksichtigen sind.In the embodiment shown according to Figure 4 the size of the respective projection 2 is dimensioned such that the ratio b / a of the projection width b in the circumferential direction to the groove opening width a in the circumferential direction is 0.12. The ratio b / c of the projection width b to the projection thickness c in the radial direction is set to 0.7. The projection width b is defined as the width of the contact surface 3. In the area of the projection 2 extending in the circumferential direction, the groove opening width a is smallest. The above values refer to the slot opening width in this area. The shape of the projection 2 has according to Figure 4 has a rectangular cross-section, taking into account the punching radii generated when punching the stator laminations.

Figur 3 zeigt den Stator 1 mit in den Nuten 13 eingespritzter isolierender Kunststoffumspritzung 14, welche die gesamte Innenwandfläche der Nuten 13 überdeckt. Im Bereich des jeweiligen Vorsprungs 2 erstreckt sich die Figure 3 shows the stator 1 with an insulating plastic encapsulation 14 injected into the grooves 13, which covers the entire inner wall surface of the grooves 13. In the area of the respective projection 2 extends

Umspritzung 14 bis zur jeweiligen nach radial innen gerichteten freien Anlagefläche 3 und bedeckt diese vollständig. Durch den jeweiligen Vorsprung 2 und die daraus gebildete Anlagefläche 3 verlängert sich die isolierte Fläche innerhalb der Nuten 13 weiter nach radial außen, so dass die Luft- und Kriechstrecke LK vergrößert wird. Zur Fixierung des Wickeldrahtes 12 innerhalb der Nuten 13 umfasst die Umspritzung Haltenasen 7, die sich radial einwärts erstrecken und ein Herausgleiten des Wickeldrahts 12 aus der Nutöffnung 15 verhindert.Overmoulding 14 up to the respective radially inwardly directed free contact surface 3 and covers this completely. Due to the respective projection 2 and the contact surface 3 formed therefrom, the insulated surface within the grooves 13 extends further radially outward, so that the clearance and creepage distance LK is increased. To fix the winding wire 12 within the grooves 13, the extrusion coating comprises retaining lugs 7 which extend radially inward and prevent the winding wire 12 from sliding out of the groove opening 15.

Der eingesetzte Wickeldraht 12 ist ein Kupferlackdraht mit einem vorbestimmten, von der Motorleistung abhängigen Drahtdurchmesser.The winding wire 12 used is an enamelled copper wire with a predetermined wire diameter that is dependent on the motor power.

Die Erfindung beschränkt sich in ihrer Ausführung nicht auf die vorstehend angegebenen bevorzugten Ausführungsbeispiele. Vielmehr ist eine Anzahl von Varianten denkbar, welche von der dargestellten Lösung auch bei grundsätzlich anders gearteten Ausführungen Gebrauch macht. Beispielsweise können die Randbereiche der sich in die Nutöffnung erstreckenden Vorsprünge abgerundet sein, um eine Einführung der Draht-Wickelnadel zu vereinfachen. Zur Vergrößerung der Kriechstrecke kann der Vorsprung jeweils auch eine axiale Nut aufweisen, die sich beispielsweise mittig entlang des Vorsprungs erstreckt.The implementation of the invention is not restricted to the preferred exemplary embodiments specified above. Rather, a number of variants are conceivable which make use of the solution shown even in the case of fundamentally different designs. For example, the edge regions of the projections extending into the groove opening can be rounded in order to simplify the introduction of the wire winding needle. To increase the creepage distance, the projection can in each case also have an axial groove which extends, for example, centrally along the projection.

Claims (8)

  1. A stator of an electric motor, having teeth (11) distributed in the circumferential direction and extending in the radial direction and grooves (13) respectively provided between the teeth (11), wherein respectively adjacent teeth (11) each form a groove opening (15) at the radial outer edge sections of said teeth, and the radial outer edge sections of the teeth (11) each have a projection (2) extending into the groove opening (15) in the circumferential direction, said projection respectively forming a free contact surface (3) directed radially inward, wherein a contact surface width in the circumferential direction corresponds to a projection width (b) in the circumferential direction, and a ratio b/a of the projection width (b) in the circumferential direction to a groove opening width (a) in the circumferential direction is in a range of 0.1 to 0.15 and a radio b/c of the projection width (b) in the circumferential direction to a projection thickness (c) in the radial direction is in a range of 0.5 to 1.0.
  2. The stator according to Claim 1, characterized in that the projection (2) respectively forms radially outward a portion of an outer jacket surface of the stator (1).
  3. The stator according to at least one of the preceding claims, characterized in that inner section (4) of the radial outer edge sections of the teeth (11), directly adjoining the projection (2) radially inward, respectively comprises a rounding.
  4. The stator according to at least one of the preceding claims, characterized in that, in an axial top view, the respective projection (2) has a rectangular cross section.
  5. The stator according to at least one of the preceding claims 1 to 4, characterized in that, in the axial direction, it comprises a plurality of stator sheets each having an axial stator sheet thickness, wherein the projection width (b) is greater than the stator sheet thickness.
  6. The stator according to at least one of the preceding claims, characterized in that the grooves (13) have an insulating overmold (14) made of plastic, which covers at least one inner wall surface of the grooves (13) and the radially inward directed free contact surface (3) of the projection (2).
  7. The stator according to at least one of the preceding claims 1 to 6, characterized in that the groove opening width (a) is smallest in the area of the respective projection (2) extending in the circumferential direction.
  8. The stator according to at least one of the preceding claims 1 to 7, characterized in that the projection width (b) in the circumferential direction is between 0.1 to 1 mm.
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US20230238838A1 (en) * 2022-01-27 2023-07-27 Ford Global Technologies, Llc Magnetically insulating stator liner system
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EP2226917A1 (en) 2009-03-07 2010-09-08 Ziehl-Abegg AG Stator for an electrical motor, method for manufacturing the same and electrical motor with such a stator
WO2012026158A1 (en) * 2010-08-26 2012-03-01 三菱電機株式会社 Rotary electric machine and stator core manufacturing device for manufacturing stator core thereof
WO2013132775A1 (en) * 2012-03-07 2013-09-12 パナソニック株式会社 Induction motor and ceiling fan equipped with same

Also Published As

Publication number Publication date
EP3289668A1 (en) 2018-03-07
DE102015106523A1 (en) 2016-11-03
CN204810005U (en) 2015-11-25
US10483811B2 (en) 2019-11-19
US20180123406A1 (en) 2018-05-03
WO2016173873A1 (en) 2016-11-03

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